412-03-1 Air Conditioning 412-03-1 REMOVAL AND INSTALLATION Clutch and Clutch Field Coil Special Tool(s) 2-Jaw Puller 205-D026 (D80L-1002-L) or equivalent Special Tool(s) Installer, A/C Compressor Field Coil 412-078 (T91L-19623-CH) Installer, A/C Compressor Coil 412-065 (T89P-19623-EH) Remover, A/C Compressor Field Coil 412-067 (T89P-19623-FH) Removal Wrench (2.5L, 3.0L and 4.0L Push Rod engines) 205-036 (T70P-4067-A) Holding Fixture, Compressor Clutch (2.3L and 4.0L SOHC engines) 412-098 (T94P-19703-AH) 1. Remove the A/C compressor (19703). For additional information, refer to Air Conditioning (A/C) Compressor 2.3L, Air Conditioning (A/C) Compressor 2.5L, Air Conditioning (A/C) Compressor 3.0L, or Air Conditioning (A/C) Compressor 4.0L in this section. Vehicles with leaf spring A/C clutch plate Remover, Differential Bearing 205-116 (T77F-4220-B1) 2. Remove the A/C clutch plate retaining bolt. 2 Remove the bolt. (Continued) Copyright 2002, Ford Motor Company Last updated: 4/20/2004
412-03-2 Air Conditioning 412-03-2 3. Remove the A/C clutch plate (2884) and the A/C clutch hub spacer (19D648). 1 Thread an 8 x 1.25 mm bolt into the A/C clutch plate to force it from the compressor shaft. 2 Lift the A/C clutch plate and the A/C clutch hub spacer from the compressor shaft. 6. Remove the A/C clutch pulley snap ring. Vehicles with 3-eye A/C clutch plate 4. Remove the A/C clutch plate retaining bolt. 2 Remove the bolt. 7. Remove the A/C clutch pulley (2E884). 5. Remove the A/C clutch (2884) and the A/C clutch hub spacer (19D648). 1 Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft. 2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft.
412-03-3 Air Conditioning 412-03-3 8. CAUTION: Do not use air tools. The A/C compressor clutch field coil can be easily damaged. Remove the A/C compressor clutch field coil (2987). 1 Note the location of the A/C compressor clutch field coil electrical connector. 2. Clean the A/C compressor clutch field coil and bearing mounting surfaces. 3. CAUTION: Do not use air tools. The A/C compressor clutch field coil can be easily damaged. Install the A/C compressor clutch field coil. 2 Install the special tool on the nose opening 1 Place the A/C compressor clutch field coil of the A/C compressor. on the A/C compressor with the A/C compressor clutch field coil electrical 3 Install the special connector correctly positioned. 4 Remove the A/C compressor clutch field 2 Place the special tool on the A/C clutch coil. field coil. 3 Place the special tool on the special 4 Use the special tool to install the A/C compressor clutch field coil until bottomed completely against the A/C compressor. Installation 1. NOTE: If installing a new A/C compressor, the A/C clutch components should be reused unless obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub and A/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage. Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat. Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth. Inspect for roughness in the A/C compressor pulley bearing. 4. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be correctly aligned during installation. Install the A/C clutch pulley.
412-03-4 Air Conditioning 412-03-4 5. Install the A/C clutch pulley snap ring with the 8. Install the A/C clutch plate retaining bolt. bevel side out. 2 Tighten the bolt. 6. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. 9. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. Vehicles with leaf spring A/C clutch plate 7. Install the A/C clutch plate. Vehicles with 3-eye A/C clutch plate 10. Install the A/C clutch plate.
412-03-5 Air Conditioning 412-03-5 11. Install the bolt. 2 Tighten the bolt. 12. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 13. Install the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor 2.3L, Air Conditioning (A/C) Compressor 2.5L, Air Conditioning (A/C) Compressor 3.0L, or Air Conditioning (A/C) Compressor 4.0L in this section.